The sizes
| Size (in) | Footprint | Cubic feet | One distributor's listing |
|---|---|---|---|
| 48 x 40 x 36 in | 48 x 40 | 40 | 1,500 lb |
| 48 x 45 x 40 in | 48 x 45 | 50 | see listing |
| 48 x 40 x 24 in | 48 x 40 | 26.7 | 1,500 lb |
| 48 x 40 x 48 in | 48 x 40 | 53.3 | 1,500 lb |
| 48 x 48 x 36 in | 48 x 48 | 48 | 1,400 lb |
| 48 x 48 x 48 in | 48 x 48 | 64 | 1,400 lb |
| 40 x 40 x 40 in | 40 x 40 | 37 | 1,300 lb |
| 36 x 36 x 36 in | 36 x 36 | 27 | 1,200 lb |
| 40 x 30 x 30 in | 40 x 30 | 20.8 | 1,200 lb |
| 48 x 24 x 28 in | 48 x 24 | 18.7 | 1,200 lb |
| 46 x 38 x 36 in octabin | Octagon | see page | 1,300 lb |
Reading a size
A gaylord size is length x width x height. Length and width are the pallet footprint. Height is the inside height. The trade lists inside dimensions, and the outside is a little larger because of the wall. When you order, say which you mean.
The last column is what one distributor lists for its triple-wall box of that size, not a maker standard. Uline lists its triple-wall 48 x 40 x 36 at 1,500 lb and its 36 x 36 x 36 at 1,200 lb. The 48 x 45 x 40 has no figure, because the only listing for it was a used five-ply box with partial bottom flaps and slip sheets. The stamp on the box is the only rating.
Which footprint
- 48 x 40 in. Standard pallet. The most common, and the easiest to place.
- 48 x 45 in. The auto supplier footprint, to match returnable containers.
- 48 x 48 in. Square pallet, bulky goods.
- 40 x 40 and 36 x 36 in. Smaller square pallets and small lots.
- Octagon. 46 x 38 in inside on a 48 x 40 in pallet.
- Half pallet. 48 x 24 in.
Height and walls
Height and wall count go together. Container Exchanger gives common gaylord heights of 30 to 36 in for 2-wall, 34 to 40 in for 3-wall, 36 to 41 in for 4-wall and 36 to 46 in for 5-wall boxes. A box outside the range for its wall count is not wrong, but ask before you assume. The spec finder marks those cases. Many pallets are also sized for 40 x 48 or 45 x 45 in, so a footprint is the first thing to confirm.
| Walls | Low (lb) | High (lb) | Low height (in) | High height (in) |
|---|---|---|---|---|
| 2-wall | 800 | 1,200 | 30 | 36 |
| 3-wall | 1,000 | 1,600 | 34 | 40 |
| 4-wall | 1,500 | 2,200 | 36 | 41 |
| 5-wall | 2,000 | 3,000 | 36 | 46 |
Facts and figures
- Typical gaylord footprints are 48 x 40, 48 x 48 or 48 x 45 inches, with sidewalls usually 24 to 50 inches high. (nelsoncompany.com, retrieved 2026-11-10.)
- Container Exchanger gives common gaylord heights of 30-36 in for 2-wall, 34-40 in for 3-wall, 36-41 in for 4-wall and 36-46 in for 5-wall boxes. (blog.containerexchanger.com, retrieved 2026-11-10.)
- Gaylord boxes range from 2 to 5 layers of cardboard, and many are sized for 40 x 48 or 45 x 45 inch pallets. (blog.containerexchanger.com, retrieved 2026-11-10.)
Terms
- pallet footprint: The box's length and width matched to a pallet, most often 48 x 40 in.
- wall count: How many layers of corrugated board form the side walls, from 2 to 5; more walls, more stacking strength.
- die-cut: Cut and scored in one press pass; most gaylords are die-cut and assembled from a tray plus a sleeve.
Checking a size you are quoted
- Ask whether the dimensions are inside or outside.
- Ask for the height with the flaps open and shut.
- Check the footprint against your pallet and your rack bay.
Pallet footprints behind the common sizes
| Footprint (in) | Rank by production | Trade named |
|---|---|---|
| 48 x 40 | 1 | Grocery Manufacturers Association standard |
| 42 x 42 | 2 | telecommunications, paint |
| 48 x 48 | 3 | drums |
| 48 x 42 | 5 | chemical, beverage |
| 40 x 40 | 6 | dairy |
| 48 x 45 | 7 | automotive |
| 44 x 44 | 8 | drums, chemical |
| 36 x 36 | 9 | beverage |
| 48 x 36 | 10 | beverage, shingles, paper |
The table is from Wikipedia, Pallet, retrieved 12 November 2026; rank 4 in that source is a military and cement entry marked as unclear, so we left it out. A gaylord is sized to sit on one of these, which is why 48 x 40, 40 x 40 and 48 x 45 in appear in catalogues while a 46 x 38 in octagon is a footprint cut to fit inside the 48 x 40.
Positions per trailer
The trailer guide gives 26 positions for 48 x 40 in pallets loaded straight and 30 turned in a 53-foot van (ATS trailer guide, retrieved 12 November 2026). We worked out that a 48 x 45 in pallet gives 26 straight and 28 turned.
Container floor waste by footprint
The share of a 40 ft ISO container floor wasted by each sanctioned footprint is 3.7 percent for 40 x 48 in, 6.7 percent for 1,000 x 1,200 mm, 8.1 percent for 45.9 x 45.9 in, 11.5 percent for 42 x 42 in, 14 percent for 43.3 x 43.3 in and 15.2 percent for 800 x 1,200 mm (Wikipedia, Pallet, retrieved 12 November 2026). For export, a 48 x 40 in box rides the most efficient of them.
Trailer dimensions behind the arithmetic
The trailer guide gives a 53-foot van an interior length of 636 in, a width of 98 to 100 in and a height of 108 to 110 in, with rolling-door vans a few inches lower, and notes that some older 48-foot vans measure 576 in (ATS trailer guide, retrieved 12 November 2026). The semi-trailer article adds that 53 ft is the standard North American length because it maximises cargo volume while remaining manoeuvrable, and that a double-deck trailer can carry about 40 pallets against 26 for a standard one (Wikipedia, Semi-trailer, retrieved 12 November 2026).